Surgical tool systems and methods

ABSTRACT

Embodiments of the present disclosure provide a surgical robot system may include an end-effector element configured for controlled movement and positioning and tracking of surgical instruments and objects relative to an image of a patient&#39;s anatomical structure. In some embodiments the end-effector and instruments may be tracked by surgical robot system and displayed to a user. In some embodiments, tracking of a target anatomical structure and objects, both in a navigation space and an image space, may be provided by a dynamic reference base located at a position away from the target anatomical structure.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part application of U.S. patentapplication Ser. No. 15/095,883 filed on Apr. 11, 2016, which isincorporated by reference in their entirety herein.

FIELD

The present disclosure generally relates to the use of robots in medicalprocedures and more particularly, the use of robots in surgicalprocedures that, for example, graphically depict anatomical structuresof a patient on a display device and the location of surgicalinstruments in relation to those anatomical structures.

BACKGROUND

Various medical procedures require the accurate localization of athree-dimensional position of a surgical instrument within the body inorder to effect optimized treatment. For example, some surgicalprocedures to fuse vertebrae require that a surgeon drill multiple holesinto the bone structure at specific locations. To achieve high levels ofmechanical integrity in the fusing system, and to balance the forcescreated in the bone structure, it is necessary that the holes aredrilled at the correct location. Vertebrae, like most bone structures,have complex shapes including non-planar curved surfaces making accurateand perpendicular drilling difficult.

Conventionally, using currently-available systems and methods, a surgeonmanually holds and positions a drill guide tube by using a guidancesystem to overlay the drill tube's position onto a three dimensionalimage of the anatomical structures of a patient, for example, bonestructures of the patient. This manual process is both tedious, timeconsuming, and error-prone. Further, whether the surgery can beconsidered successful largely depends upon the dexterity of the surgeonwho performs it. Thus, there is a need for the use of robot assistedsurgery to more accurately position surgical instruments and moreaccurately depict the position of those instruments in relation to theanatomical structures of the patient.

Currently, limited robotic assistance for surgical procedures isavailable. For example, certain systems allow a user to control arobotic actuator. These systems convert a surgeon's gross movements intomicro-movements of the robotic actuator to more accurately position andsteady the surgical instruments when undergoing surgery. Although thesesystems may aid in eliminating hand tremor and provide the surgeon withimproved ability to work through a small opening, like many of therobots commercially available today, these systems are expensive,obtrusive, and require a cumbersome setup for the robot in relation tothe patient and the user (e.g., a surgeon). Further, for certainprocedures, such as thoracolumbar pedicle screw insertion, theseconventional methods are known to be error-prone and tedious.

The current systems have many drawbacks including but not limited to thefact that autonomous movement and precise placement of a surgicalinstrument can be hindered by a lack of mechanical feedback and/or aloss of visual placement once the instrument is submerged within aportion of a patient. These drawbacks make the existing surgicalapplications error prone resulting in safety hazards to the patient aswell as the surgeon during surgical procedures.

In addition, current robot assisted systems suffer from otherdisadvantages. The path and angle in which a surgical instrument isinserted into a patient (a trajectory of the instrument) may be limiteddue to the configuration of the robot arm and the manner in which it canmove. For example, some current systems may not have enough range ofmotion or movement to place the surgical instrument at a trajectoryideal for placement into the patient and/or at a position that allowsthe surgeon an optimal view for performing the surgery.

The present disclosure overcomes the disadvantages of current robotassisted surgical applications. For example, the present disclosureallows for precisely locating anatomical structures in open,percutaneous, or minimally invasive surgery (MIS) procedures andpositioning surgical instruments or implants during surgery. Inaddition, the present disclosure may improve stereotactic surgicalprocedures by allowing for identification and reference to a rigidanatomical structure relative to a pre-op computerized tomography (CT)scan, intra-op CT scan or fluoroscopy/x-ray based image of the anatomy.Further, the present disclosure may integrate a surgical robotic arm, alocal positioning system, a dynamic reference base, and planningsoftware to assist a surgeon in performing medical procedures in a moreaccurate and safe manner thereby reducing the error pronecharacteristics of current robot assisted systems and methods.

SUMMARY

Exemplary embodiments of the present disclosure may provide a surgicalrobot system comprising a dynamic reference base (DRB) attached topatient fixture instrument, wherein the dynamic reference base has oneor more DRB markers indicating a position of the patient fixtureinstrument in a navigational space, and a registration fixture, havingone or more registration markers, indicating a location of a targetanatomical structure in the navigational space and one or moreregistration fiducials indicating a location of the target anatomicalstructure in an image space. The surgical robot system may be configuredto associate the location of the target anatomical structure with thepatient fixture instrument in the navigational space and the image spacetaking into account a relationship between the one or more registrationmarkers and the one or more fiducials and the relationship between theregistration makers and the DRB markers. The patient fixture instrumentis located in a position different from the target anatomical structure.

DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate a surgical robot in accordance with an exemplaryembodiment.

FIG. 1C illustrates a portion of a surgical robot with control of thetranslation and orientation of the end-effector in accordance with anexemplary embodiment.

FIG. 1D illustrates a partial view of a surgical robot having aplurality of optical markers mounted for calibration and trackingmovement in accordance with an exemplary embodiment.

FIG. 2 illustrates a surgical robot operating on a patient in accordancewith an exemplary embodiment.

FIG. 3 illustrates a surgical robot in accordance with an exemplaryembodiment.

FIG. 4 illustrates a portion of a surgical robot in accordance with anexemplary embodiment.

FIG. 5 illustrates a block diagram of a surgical robot in accordancewith an exemplary embodiment.

FIG. 6 illustrates a surgical robot in accordance with an exemplaryembodiment.

FIGS. 7A-C illustrate an end-effector in accordance with an exemplaryembodiment.

FIGS. 8A-C illustrate an instrument and an instrument assembly inaccordance with an exemplary embodiment.

FIGS. 9A-B illustrate an end-effector in accordance with an exemplaryembodiment.

FIG. 10A-B illustrate an end-effector and instrument assembly inaccordance with an exemplary embodiment.

FIG. 11 illustrates an instrument and guide tube in accordance with anexemplary embodiment.

FIGS. 12A-C illustrate portions of an end-effector and robot arm inaccordance with an exemplary embodiment.

FIG. 13 illustrates portions of an end-effector and robot arm inaccordance with an exemplary embodiment.

FIG. 14 illustrates a dynamic reference base, an imaging array, andother components in accordance with an exemplary embodiment.

FIG. 15 illustrates a method of registration in accordance with anexemplary embodiment.

FIG. 16 illustrates a registration fixture device in accordance with anexemplary embodiment.

FIG. 17 illustrates a registration fixture device and dynamic referencebase in relation to a target anatomical structure in accordance with anexemplary embodiment.

FIG. 18 illustrates a registration fixture device, dynamic referencebase, and patient fixture instrument in relation to a target anatomicalstructure in accordance with an exemplary embodiment.

DETAILED DESCRIPTION

It is to be understood that the present disclosure is not limited in itsapplication to the details of construction and the arrangement ofcomponents set forth in the description herein or illustrated in thedrawings. The teachings of the present disclosure may be used andpracticed in other embodiments and practiced or carried out in variousways. Also, it is to be understood that the phraseology and terminologyused herein is for the purpose of description and should not be regardedas limiting. The use of “including,” “comprising,” or “having” andvariations thereof herein is meant to encompass the items listedthereafter and equivalents thereof as well as additional items. Unlessspecified or limited otherwise, the terms “mounted,” “connected,”“supported,” and “coupled” and variations thereof are used broadly andencompass both direct and indirect mountings, connections, supports, andcouplings. Further, “connected” and “coupled” are not restricted tophysical or mechanical connections or couplings.

The following discussion is presented to enable a person skilled in theart to make and use embodiments of the present disclosure. Variousmodifications to the illustrated embodiments will be readily apparent tothose skilled in the art, and the principles herein can be applied toother embodiments and applications without departing from embodiments ofthe present disclosure. Thus, the embodiments are not intended to belimited to embodiments shown, but are to be accorded the widest scopeconsistent with the principles and features disclosed herein. Thefollowing detailed description is to be read with reference to thefigures, in which like elements in different figures have like referencenumerals. The figures, which are not necessarily to scale, depictselected embodiments and are not intended to limit the scope of theembodiments. Skilled artisans will recognize the examples providedherein have many useful alternatives and fall within the scope of theembodiments.

FIGS. 1A, 1B, and 1D illustrate a surgical robot system 100 inaccordance with an exemplary embodiment. Surgical robot system 100 mayinclude a surgical robot 102, a robot arm 104, a base 106, a housing108, a display 110, an end-effector or end-effectuator 112, a guide tube114, a tracking array 116, and tracking markers 118.

FIG. 1C illustrates a portion of a surgical robot system 100 withcontrol of the translation and orientation of end-effector 112 inaccordance with an exemplary embodiment.

As shown in FIGS. 1A and 1B, surgical robot 102 can comprise a display110 and a housing 108. Display 110 can be attached to the surgical robot102 and in other exemplary embodiments, display 110 can be detached fromsurgical robot 102, either within a surgical room with the surgicalrobot 102, or in a remote location. In some embodiments, housing 108 cancomprise robot arm 104 and an end-effector 112. End-effector 112 may becoupled to the robot arm 104 and controlled by at least one motor. Inexemplary embodiments, end-effector 112 can comprise a surgicalinstrument used to perform surgery on a patient 210. In exemplaryembodiments, end-effector 112 can be coupled to the surgical instrument.As used herein, the term “end-effector” is used interchangeably with theterm “effectuator element.” In some embodiments, end-effector 112 cancomprise any known structure for effecting the movement of the surgicalinstrument in a desired manner.

FIG. 1C illustrates a portion of a surgical robot 102 with control ofthe translation and orientation of end-effector 112 in accordance withan exemplary embodiment. As shown, some embodiments include a surgicalrobot system 100 capable of using robot 102 with an ability to moveend-effector 112 along x-, y-, and z-axes (see 126, 128, 130 in FIG.1C). In this embodiment, x-axis 126 can be orthogonal to y-axis 128 andz-axis 130, y-axis 128 can be orthogonal to x-axis 126 and z-axis 130,and z-axis 130 can be orthogonal to x-axis 126 and y-axis 128. In anexemplary embodiment, robot 102 can be configured to effect movement ofend-effector 112 along one axis independently of the other axes. Forexample, in some exemplary embodiments, robot 102 can cause theend-effector 112 to move a given distance of 500 mm or more along x-axis126 without causing any substantial movement of end-effector 112 alongy-axis 128 or z-axis 130. As used in this context “substantial” may meana deviation of more than two degrees or 2 mm from an intended path orsome other predetermined deviation that may be appropriate for thesurgical application.

In some further exemplary embodiments, end-effector 112 can beconfigured for selective rotation about one or more of x-axis 126,y-axis 128, and a Z Frame axis 130 (such that one or more of the EulerAngles (e.g., roll, pitch, and/or yaw) associated with end-effector 112can be selectively controlled). For example, roll 122 is selectiverotation about y-axis 128 without substantial deviation about or alongx-axis 126 or Z Frame axis 130; pitch 120 is selective rotation aboutx-axis 126 without substantial deviation about or along y-axis 128 or ZFrame axis 130. In some exemplary embodiments, during operation,end-effector 112 and/or the surgical instrument may be aligned with aselected orientation axis (labeled “Z Tube” 64 in FIG. 1C) that can beselectively varied and monitored by robot system 100. End-effector 112may contain a linear actuator that causes guide tube 114 to move in ZTube axis 64 direction.

In some exemplary embodiments, selective control of the translation andorientation of end-effector 112 can permit performance of medicalprocedures with significantly improved accuracy compared to conventionalrobots that utilize, for example, a six degree of freedom robot armcomprising only rotational axes. For example, in some exemplaryembodiments, as shown in FIG. 2, surgical robot system 100 may be usedto operate on patient 210, and robot arm 104 that can be positionedabove the body of patient 210, with end-effector 112 selectively angledrelative to the z-axis toward the body of patient 210.

In some exemplary embodiments, the position of the surgical instrumentcan be dynamically updated so that surgical robot 102 can be aware ofthe location of the surgical instrument at all times during theprocedure. Consequently, in some exemplary embodiments, surgical robot102 can move the surgical instrument to the desired position quickly,with minimal damage to patient 210, and without any further assistancefrom a physician (unless the physician so desires). In some furtherembodiments, surgical robot 102 can be configured to correct the path ofthe surgical instrument if the surgical instrument strays from theselected, preplanned trajectory. In some exemplary embodiments, surgicalrobot 102 can be configured to permit stoppage, modification, and/ormanual control of the movement of end-effector 112 and/or the surgicalinstrument. Thus, in use, in exemplary embodiments, a physician or otheruser can operate the system 100, and has the option to stop, modify, ormanually control the autonomous movement of end-effector 112 and/or thesurgical instrument. Further details of surgical robot system 100including the control and movement of a surgical instrument by surgicalrobot 102 can be found in co-pending U.S. patent application Ser. No.13/924,505 from which this application claims priority under 35 U.S.C. §120, and which is incorporated herein by reference in its entirety.

As shown in FIGS. 1B and 1D, in exemplary embodiments, robotic surgicalsystem 100 can comprise a plurality of tracking markers 118 configuredto track the movement of robot arm 104, end-effector 112, and/or thesurgical instrument in three dimensions. It should be appreciated thatthree dimensional positional information from tracking markers 118 canbe used in conjunction with the one dimensional linear or rotationalpositional information from absolute or relative conventional linear orrotational encoders on each axis of robot 102 to maintain a high degreeof accuracy. In exemplary embodiments, the plurality of tracking markers118 can be mounted (or otherwise secured) thereon an outer surface ofthe robot 102, such as, for example and without limitation, on base 106of robot 102, or robot arm 104 (see for example FIG. 1B). Further, inexemplary embodiments, the plurality of tracking markers 118 can bepositioned on base 106 of robot 102 spaced from surgical field 208 toreduce the likelihood of being obscured by the surgeon, surgical tools,or other parts of robot 102. In exemplary embodiments, at least onetracking marker 118 of the plurality of tracking markers 118 can bemounted or otherwise secured to end-effector 112 (see for example FIG.1D).

In exemplary embodiments, system 100 can use tracking informationcollected relative to the robot base 106 to calculate the orientationand coordinates of the surgical instrument held in the tube 114 based onencoder counts along x-axis 126, y-axis 128, z-axis 130, Z-tube axis124, and the roll 122 and pitch 120 axes.

In exemplary embodiments, one or more of markers 118 may be opticalmarkers and at least one optical marker may be positioned on the robot102 between the base 106 of the robot 102 and end-effector 112 insteadof, or in addition to, other markers 118 on base 106. In someembodiments, the positioning of one or more tracking markers 118 onend-effector 112 can maximize the accuracy of the positionalmeasurements by serving to check or verify the position of end-effector112 (calculated from the positional information of markers 118 on base106 and encoder counts of z-axis 130, x-axis 126, y-axis 128, roll axis122, pitch axis 120, and Z-tube axis 124).

In exemplary embodiments, the at least one tracking marker 118 can bemounted to a portion of the robot 102 that effects movement ofend-effector 112 and/or the surgical instrument along the x-axis toenable the at least one tracking marker 118 to move along x-axis 126 asend-effector 112 and the surgical instrument move along the x-axis 126(see FIG. 1D). In exemplary embodiments, placement of tracking markers118 as described can reduce the likelihood of a surgeon blocking one ormore tracking markers 118 from the cameras or detection device, or oneor more tracking markers 118 becoming an obstruction to surgery.

In exemplary embodiments, because of the high accuracy in calculatingthe orientation and position of end-effector 112 based on an output ofone or more of tracking markers 118 and/or encoder counts from eachaxis, it can be possible to very accurately determine the position ofend-effector 112. For example, in exemplary embodiments, withoutrequiring knowledge of the counts of axis encoders for the z-axis 130(which is between the x-axis 126 and the base 106), knowing only theposition of markers 118 on the x-axis 126 and the counts of encoders onthe y-axis 128, roll axis 62, pitch axis 120, and Z-tube axis 124 canenable computation of the position of end-effector 112. In someembodiments, the placement of markers 118 on any intermediate axis ofrobot 102 can permit the exact position of end-effector 112 to becalculated based on location of such markers 118 and counts of encoderson axes (126, 120, 122, and 124) between markers 118 and end-effector112. Further details of surgical robot system 100 including the control,movement and tracking of surgical robot 102 and of a surgical instrumentcan be found in co-pending U.S. patent application Ser. No. 13/924,505from which this application claims priority under 35 U.S.C. § 120, andwhich is incorporated herein by reference in its entirety as earlierrecited.

Exemplary embodiments include one or more markers coupled to thesurgical instrument as described in greater detail below. In exemplaryembodiments, these markers as well as markers 118 can compriseconventional infrared light-emitting diodes or an Optotrak® diodecapable of being tracked using a commercially available infrared opticaltracking system such as Optotrak®. Optotrak® is a registered trademarkof Northern Digital Inc., Waterloo, Ontario, Canada. In otherembodiments, markers 118 can comprise conventional reflective spherescapable of being tracked using a commercially available optical trackingsystem such as Polaris Spectra. Polaris Spectra is also a registeredtrademark of Northern Digital, Inc.

Referring to FIG. 2, surgical robot system 100 is shown and furtherincludes cameras 200, a camera arm 202, camera arm joints 204 and 206.FIG. 2 further depicts surgical field 208 and patient 210.

In exemplary embodiments, light emitted from and/or reflected by markers118 and markers on the surgical instrument can be read by camera 200 andcan be used to monitor the location and movement of robot 102 (see forexample camera 200 mounted on the camera arm 202 and capable of movementthrough camera arm joint 204 and camera arm joint 206 shown in FIG. 2).In exemplary embodiments, markers 118 and the markers on the surgicalinstrument can comprise a radio-frequency and/or electromagneticreflector or transceiver and the camera 200 can include or be replacedby a radio-frequency and/or electromagnetic transceiver.

FIG. 3 illustrates a surgical robot system 300 and camera stand 302consistent with an exemplary embodiment of the present disclosure.Surgical robot system 300 may comprise display 304, upper arm 306, lowerarm 308, end-effector 310, vertical column 312, casters 314, cabinet316, tablet drawer 318, connector panel 320, control panel 322, and ring324. Camera stand 302 may comprise camera 326. These components aredescribed in greater with respect to FIG. 5.

FIG. 4 illustrates a base 400 consistent with an exemplary embodiment ofthe present disclosure. Base 400 may be a portion of surgical robotsystem 300 and comprise cabinet 316. Cabinet 316 may house certaincomponents of surgical robot system 300 including but not limited to abattery 402, a power distribution module 404, a platform interface boardmodule 406, a computer 408, a handle 412, and a tablet drawer 414. Theconnections and relationship between these components is described ingreater detail with respect to FIG. 5.

FIG. 5 illustrates a block diagram of certain components of an exemplaryembodiment of surgical robot system 300. Surgical robot system 300 maycomprise platform subsystem 502, computer subsystem 504, motion controlsubsystem 506, and tracking subsystem 532. Platform subsystem 502 mayfurther comprise battery 402, power distribution module 404, platforminterface board module 406, and tablet charging station 534. Computersubsystem 504 may further comprise computer 408, display 304, andspeaker 536. Motion control subsystem 506 may further comprise drivercircuit 508, motors 510, 512, 514, 516, 518, stabilizers 520, 522, 524,526, end-effector 310, and controller 538. Tracking subsystem 532 mayfurther comprise position sensor 540 and camera converter 542. System300 may also comprise a foot pedal 544 and tablet 546.

Input power is supplied to system 300 via a power source 548 which maybe provided to power distribution module 404. Power distribution module404 receives input power and is configured to generate different powersupply voltages that are provided to other modules, components, andsubsystems of system 300. Power distribution module 404 may beconfigured to provide different voltage supplies to platform interfacemodule 406, which may be provided to other components such as computer408, display 304, speaker 536, driver 508 to, for example, power motors512, 514, 516, 518 and end-effector 310, motor 510, ring 324, cameraconverter 542, and other components for system 300 for example, fans forcooling the electrical components within cabinet 316.

Power distribution module 404 may also provide power to other componentssuch as tablet charging station 534 that may be located within tabletdrawer 318. Tablet charging station 534 may be in wireless or wiredcommunication with tablet 546 for charging table 546. Tablet 546 may beused by a surgeon consistent with the present disclosure and describedherein.

Power distribution module 404 may also be connected to battery 402,which serves as temporary power source in the event that powerdistribution module 404 does not receive power from input power 548. Atother times, power distribution module 404 may serve to charge battery402 if necessary.

Other components of platform subsystem 502 may also include connectorpanel 320, control panel 322, and ring 324. Connector panel 320 mayserve to connect different devices and components to system 300 and/orassociated components and modules. Connector panel 320 may contain oneor more ports that receive lines or connections from differentcomponents. For example, connector panel 320 may have a ground terminalport that may ground system 300 to other equipment, a port to connectfoot pedal 544 to system 300, a port to connect to tracking subsystem532, which may comprise position sensor 540, camera converter 542, andcameras 326 associated with camera stand 302. Connector panel 320 mayalso include other ports to allow USB, Ethernet, HDMI communications toother components, such as computer 408.

Control panel 322 may provide various buttons or indicators that controloperation of system 300 and/or provide information regarding system 300.For example, control panel 322 may include buttons to power on or offsystem 300, lift or lower vertical column 312, and lift or lowerstabilizers 520-526 that may be designed to engage casters 314 to locksystem 300 from physically moving. Other buttons may stop system 300 inthe event of an emergency, which may remove all motor power and applymechanical brakes to stop all motion from occurring. Control panel 322may also have indicators notifying the user of certain system conditionssuch as a line power indicator or status of charge for battery 402.

Ring 324 may be a visual indicator to notify the user of system 300 ofdifferent modes that system 300 is operating under and certain warningsto the user.

Computer subsystem 504 includes computer 408, display 304, and speaker536. Computer 504 includes an operating system and software to operatesystem 300. Computer 504 may receive and process information from othercomponents (for example, tracking subsystem 532, platform subsystem 502,and/or motion control subsystem 506) in order to display information tothe user. Further, computer subsystem 504 may also include speaker 536to provide audio to the user.

Tracking subsystem 532 may include position sensor 504 and converter542. Tracking subsystem 532 may correspond to camera stand 302 includingcamera 326 as described with respect to FIG. 3. Position sensor 504 maybe camera 326. Tracking subsystem may track the location of certainmarkers that are located on the different components of system 300and/or instruments used by a user during a surgical procedure. Thistracking may be conducted in a manner consistent with the presentdisclosure including the use of infrared technology that tracks thelocation of active or passive elements, such as LEDs or reflectivemarkers, respectively. The location, orientation, and position ofstructures having these types of markers may be provided to computer 408which may be shown to a user on display 304. For example, a surgicalinstrument having these types of markers and tracked in this manner(which may be referred to as a navigational space) may be shown to auser in relation to a three dimensional image of a patient's anatomicalstructure.

Motion control subsystem 506 may be configured to physically movevertical column 312, upper arm 306, lower arm 308, or rotateend-effector 310. The physical movement may be conducted through the useof one or more motors 510-518. For example, motor 510 may be configuredto vertically lift or lower vertical column 312. Motor 512 may beconfigured to laterally move upper arm 308 around a point of engagementwith vertical column 312 as shown in FIG. 3. Motor 514 may be configuredto laterally move lower arm 308 around a point of engagement with upperarm 308 as shown in FIG. 3. Motors 516 and 518 may be configured to moveend-effector 310 in a manner such that one may control the roll and onemay control the tilt, thereby providing multiple angles thatend-effector 310 may be moved. These movements may be achieved bycontroller 538 which may control these movements through load cellsdisposed on end-effector 310 and activated by a user engaging these loadcells to move system 300 in a desired manner.

Moreover, system 300 may provide for automatic movement of verticalcolumn 312, upper arm 306, and lower arm 308 through a user indicatingon display 304 (which may be a touchscreen input device) the location ofa surgical instrument or component on three dimensional image of thepatient's anatomy on display 304. The user may initiate this automaticmovement by stepping on foot pedal 544 or some other input means.

FIG. 6 illustrates a surgical robot system 600 consistent with anexemplary embodiment. Surgical robot system 600 may compriseend-effector 602, robot arm 604, guide tube 606, instrument 608, androbot base 610. Instrument tool 608 may be attached to a tracking array612 and have an associated trajectory 614. Trajectory 614 may representa path of movement that instrument tool 608 is configured to travel onceit is secured in guide tube 606, for example, a path of insertion ofinstrument tool 608 into a patient. In an exemplary operation, robotbase 610 may be configured to be in electronic communication with robotarm 604 and end-effector 602 so that surgical robot system 600 mayassist a user (for example, a surgeon) in operating on a patient.Surgical robot system 600 may be consistent with previously describedsurgical robot system 100 and 300.

A tracking array 612 may be mounted on instrument 608 to monitor thelocation and orientation of instrument tool 608. As described in greaterdetail below with respect to FIG. 8A, tracking array 612 may be attachedto an instrument assembly 802 and may comprise markers 804. Instrumentassembly 802 may house instrument 608 as described in further detailbelow with respect to FIG. 8B. Markers 804 may be, for example, lightemitting diodes and/or other types of markers as described consistentwith the present disclosure. The tracking devices may be one or moreline of sight devices associated with the surgical robot system. As anexample, the tracking devices may be cameras associated with thesurgical robot system and may also track tracking array 612 for adefined domain or relative orientations of the instrument in relation tothe robot arm, the robot base, and/or a patient. The tracking devicesmay be consistent with those structures described in connection withcamera stand 302 and tracking subsystem 532.

FIGS. 7A, 7B, and 7C illustrate a top view, front view, and side view,respectively, of end-effector 602 consistent with an exemplaryembodiment. End-effector 602 may additionally comprise one or moremarkers 702. Markers 702 may be light emitting diodes or other types ofmarkers that have been previously described.

Markers 702 may be disposed on end-effector 602 in a manner such thatthe markers are visible by one or more tracking devices associated withthe surgical robot system. The tracking devices may track end-effector602 as it moves to different positions and viewing angles by followingthe movement of tracking markers 702. The location of markers 702 and/orend-effector 602 may be shown on a display associated with the surgicalrobot system, for example, display 110 as shown in FIG. 1 and/or display304 shown in FIG. 3. This display may allow a user to ensure thatend-effector 602 is in a desirable position in relation to robot arm604, robot base 610, the patient, and/or the user.

For example, as shown in FIG. 7A, markers 702 may be placed around thesurface of end-effector 602 so that a tracking device placed away fromthe surgical field and facing toward the robot and surgical field isable to view at least 3 of the markers 702 through a range of commonorientations of the end effector relative to the tracking device. Forexample, distribution of markers in this way allows end-effector 602 tobe monitored by the tracking devices when end-effector 602 is rotated by+/−135 degrees about the z-axis of the surgical robot system.

In addition, in exemplary embodiments, end-effector 602 may be equippedwith infrared (IR) receivers that can detect when an external camera isgetting ready to read markers 702. Upon this detection, end-effector 602may then illuminate markers 702. The detection by the IR receivers thatthe external camera is ready to read markers 702 may signal the need tosynchronize a duty cycle of markers 702, which may be light emittingdiodes, to an external camera. This may also allow for lower powerconsumption by the robotic system as a whole, whereby markers 702 wouldonly be illuminated at the appropriate time instead of being illuminatedcontinuously. Further, in exemplary embodiments, markers 702 may bepowered off to prevent interference with other navigation tools, such asdifferent types of surgical instruments.

FIG. 8A depicts instrument 608 and instrument assembly 802. Instrumentassembly 802 may further comprise tracking array 612, markers 804, anouter sleeve 806, one or more grooves 808, a tip 810, and an opening812. Instrument 608 may include tip 814. Ultimately, as explained ingreater detail with respect to FIGS. 10A and 10B, instrument assembly802, which may house instrument 608, may be inserted into guide tube606.

Markers 804 may be of any type described herein including but notlimited to light emitting diodes or reflective spheres. Markers 804 aremonitored by tracking devices associated with the surgical robot systemand may be one or more line of sight cameras. The cameras may track thelocation of instrument assembly 802 based on the position andorientation of tracking array 612 and markers 804. A user, such as asurgeon, may orient instrument assembly 612 in a manner so that trackingarray 612 and markers 804 are sufficiently recognized by the trackingdevices to display instrument assembly 802 and markers 804 on, forexample, display 110 of the exemplary surgical robot system. The mannerin which a surgeon may place instrument assembly 802 into guide tube 606and adjust instrument assembly 802 is explained in greater detail below.

Instrument assembly 802 may also include outer sleeve 806. Outer sleeve806 may contain one or more grooves 808 and tip 810. As explained ingreater detail below, tip 810 may contain lead-in features that assistin lining up one of grooves 808 with certain features of guide tube 606to orient instrument assembly 802. The manner in which a user insertsinstrument assembly 802 into guide tube 606 is explained in furtherdetail with respect to FIGS. 10A and 10B.

FIG. 8A also depicts instrument 608. Instrument 608 may be a surgicaltool or implement associated with the surgical robot system. Instrument608 may be inserted into instrument assembly 802 by inserting tip 814into opening 812. Once inside instrument assembly 802, instrument 608 isfree to rotate about its shaft axis and move in an axial direction asdetermined by the user. FIG. 8B depicts instrument 608 inserted intoinstrument assembly 802. FIG. 8C depicts a bottom view of instrument 608inserted into instrument assembly 802.

FIGS. 9A and 9B illustrate end-effector 602 consistent with an exemplaryembodiment. End-effector 602 may comprise sensor 902 and sensor cover904. The surgical robot system may contain circuitry that is configuredto restrict or prevent robot arm 604 from moving when an instrument (forexample, instrument 608) is in guide tube 606. Restricting or preventingmovement of robot arm 604 while instrument 608 or another surgicalinstrument is in guide tube 606 may prevent a potentially hazardoussituation to the patient and/or the user of the system while a sharpinstrument is engaged in guide tube 606.

Sensor 902 may be configured such that it detects the presence of aninstrument in guide tube 606. As shown in FIGS. 9A and 9B, sensor 902may be embedded in an upper portion of guide tube 606. Sensor 902 may bea hall effect sensor using magnetic properties of the instrument todetect the instrument's presence in guide tube 606. Sensor 902 may becovered by sensor cover 904 as shown in FIGS. 9A and 9B.

Sensor 902 may detect the instrument's presence in guide tube 606. Byway of example and in no way intended to limit the manner in which thesensor may be implemented, sensor 902 may be a capacitive or resistivesensor which uses changes in the electrical properties of guide tube606, such as its impedance, when an instrument is present in guide tube606. Further, sensor 902 may be a mechanical switch, such as an actuatedor strain gauge. Further still, sensor 902 may be an optical sensor todetermine the presence of an instrument in guide tube 606. In addition,sensor 902 may be an inductive sensor that uses magnetic field changesto determine the presence of an instrument in guide tube 606.

Sensor 902 may be configured to send a signal (sensor signal) tocircuitry associated with the surgical robot system. Once the surgicalrobot system receives such a sensor signal, surgical robot system mayrestrict or prevent movement of robot arm 604 while an instrument isinside guide tube 606.

In a further embodiment, the surgical robot system may also disabletracking markers 702 in response to the sensor signal. This disablingresponse would prevent the undesirable situation of optical interferenceand partial occlusion from tracking markers 702, particularly iftracking markers are light emitting diodes.

FIGS. 10A and 10B illustrate a top view of end-effector 602 whileinstrument assembly 802 is inside guide tube 606 consistent with anexemplary embodiment. End-effector 602 may further comprise spring 1002and ball detent 1004, both of which may be disposed in or near guidetube 606. FIGS. 10A and 10B also depict outer sleeve 806 and grooves808.

Instrument 608 may be disposed within instrument assembly 802 asdescribed with respect to FIG. 13. While instrument 608 is disposed ininstrument assembly 802, instrument assembly 802 may be inserted inguide tube 606. Guide tube 606 may restrict the movement of instrumentassembly 802 in a manner such that tracking array 612 remains inessentially the same orientation relative to robot arm 604 and robotbase 612 so that tracking devices can display the location of instrumentassembly 802 on, for example, display 110. Instrument 608 may be free torotate about its shaft without affecting rotation of the array and maymove in a direction consistent with trajectory 614.

Specifically, instrument assembly 802 (after instrument 608 is insertedtherein), may be inserted into guide tube 606. Structures on tip 810 ofouter sleeve 806 may cause one of grooves 808 to line up and engage withball detent 1004. Ball detent 1004 may be in communication with spring1002 such that when a force is applied to ball detent 1004, it is ableto move backward against spring 1002 and when the force is removedspring 1002 moves ball detent 1004 in a forward direction. When balldetent 1004 engages a groove 808 it may move forward into that groove808 and spring 1002 may apply sufficient force on ball detent 1004 sothat ball detent is biased towards that groove 808. With ball detent1004 lined up and engaged with one of grooves 808, instrument assembly802 is inserted further into guide tube 606. FIG. 10B depicts a groove808 engaged with ball detent 1004.

Instrument 608 may freely rotate about its shaft and move along the pathof trajectory 614 within instrument assembly 802. Instrument assembly802 may be restricted from rotating within guide tube 606 while a groove808 is engaged with ball detent 1004. The rotational position ofinstrument assembly 802 within guide tube 606 may be chosen such thattracking array 612 is adequately visible to the tracking devices inorder to properly display the position of instrument 608 on, forexample, display 110 of the surgical robot system.

While rotational movement of instrument assembly 802 inside guide tube606 may be restricted, the rotational position of instrument assembly802 may be adjusted. For example, instrument assembly 802 may beadjusted so that tracking array 612 is in a better position to bevisible by the tracking devices. In an exemplary embodiment, sufficientrotational force may be applied to instrument assembly 802 to disengageball detent 1004 from a groove 808. Ball detent 1004 may move backwardsupon disengaging with a groove 808. This disengagement is depicted inFIG. 10A. Once disengaged, the rotational position of instrumentassembly 802 may be adjusted so that ball detent 1004 moves forward andengages a different groove 808.

Ball detent 1004 and the one or more grooves 808 may be configured suchthat movement along the path of trajectory 614 is not restricted. Thisconfiguration may allow instrument assembly 802 to move along a path oftrajectory 614, while guide tube 606 restricts rotational movement ofinstrument assembly 802 to maintain a fixed orientation of trackingarray 612 in relation to the tracking devices.

Ball detent 1004 has been described in relation to spring 1002 and beinga spring plunger type of structure. However, it is understood that otherstructures may be used to restrict rotational movement of instrumentassembly 802 in guide tube 606 in order to maintain an orientation oftracking array 612. For example, such structures may include and are notlimited to a coil spring, wave spring, flexture, torsional springmounted to a lever, or a compressible material. Further, ball detent1004 and spring 1002 have been described as being part of guide tube606, however, ball detent 1004 and spring 1002 may be disposed oninstrument assembly 802 and engage with complimentary mechanismsassociated with end-effector 602 or guide tube 606 to similarly restrictthe rotation movement of instrument assembly 802.

FIG. 11 illustrates end-effector 602, instrument 608, instrumentassembly 1102, tracking array 1104, and guide tube 606 consistent withan exemplary embodiment. Instrument assembly 1102 may further comprisegroove 1106. Guide tube 606 may further comprise channel 1108.

As described previously, rotational movement of instrument assembly 802may be restricted when it is received by guide tube 606. In an exemplaryembodiment to restrict movement of an instrument assembly while inside aguide tube, instrument assembly 1102 may have groove 1106 configured toengage channel 1108 of guide tube 606 to similarly restrict rotationalmovement of instrument assembly 1102 when received by guide tube 606.Once groove 1106 is engaged with channel 1108, instrument assembly 1102is restricted from rotating about its shaft axis while instrumentassembly 1102 is inside guide tube 606.

Other methods and components may be used to restrict the rotationalmovement of an instrument assembly while inside a guide tube. Forexample, one or more cylindrical rollers may be used that is configuredwith roller axis perpendicular to the instrument shaft to roll and allowfor axial movement of an instrument assembly along the path oftrajectory 614 but is configured to remain stationary when attempts aremade to rotationally move instrument assembly within guide tube 606.This configuration would have the effect of fixing the orientation oftracking array 612. The roller may be made of a flexible material andheld rigidly protruding into guide tube 606 to engage with an outersleeve of the instrument assembly. The roller may also be made of arigid material and spring loaded, pushing into guide tube 606 to engagewith the instrument assembly. Moreover, the roller may be disposed on aninstrument assembly and engage guide tube 606 when the instrumentassembly is inserted into guide tube 606.

As another exemplary embodiment, rotation of an outer sleeve ofinstrument assembly may be restricted from rotating but allowing foraxial movement through the use of anisotropic surface textures for theouter sleeve and guide tube 606. This texture pattern may allow fordifferent friction forces associated with rotation of the outer sleeveand axial movement so that a user may need to apply a relatively higherforce to rotationally move the instrument assembly compared to movingthe instrument assembly in an axial direction consistent with trajectory614.

FIGS. 12A-C illustrate end-effector 602 and a portion of robot arm 604consistent with an exemplary embodiment. End-effector 602 may furthercomprise body 1202 and clamp 1204. Clamp 1204 may comprise handle 1206,balls 1208, spring 1210, and lip 1212. Robot arm 604 may furthercomprise depressions 1214, mounting plate 1216, lip 1218, and magnets1220.

End-effector 602 may mechanically interface and/or engage with thesurgical robot system and robot arm 604 through one or more couplings.For example, end-effector 602 may engage with robot arm 604 through alocating coupling and/or a reinforcing coupling. Through thesecouplings, end-effector 602 may fasten with robot arm 604 outside aflexible and sterile barrier. In an exemplary embodiment, the locatingcoupling may be a magnetically kinematic mount and the reinforcingcoupling may be a five bar over center clamping linkage.

With respect to the locating coupling, robot arm 1002 may comprisemounting plate 1716, which may be non-magnetic material, one or moredepressions 1214, lip 1218, and magnets 1220. Magnet 1220 is mountedbelow each of depressions 1214. Portions of clamp 1204 may comprisemagnetic material and be attracted by one or more magnets 1220. Throughthe magnetic attraction of clamp 1204 and robot arm 604, balls 1208become seated into respective depressions 1214. For example, balls 1208as shown in FIG. 12B would be seated in depressions 1214 as shown inFIG. 12A. This seating may be considered a magnetically-assistedkinematic coupling. Magnets 1220 may be configured to be strong enoughto support the entire weight of end-effector 602 regardless of theorientation of end-effector 602. The locating coupling may be any styleof kinematic mount that uniquely restrains six degrees of freedom.

With respect to the reinforcing coupling, portions of clamp 1204 may beconfigured to be a fixed ground link and as such clamp 1204 may serve asa five bar linkage. Closing clamp handle 1206 may fasten end-effector602 to robot arm 604 as lip 1212 and lip 1218 engage clamp 1204 in amanner to secure end-effector 602 and robot arm 604. When clamp handle1206 is closed, spring 1210 may be stretched or stressed while clamp1204 is in a locked position. The locked position may be a position thatprovides for linkage past center. Because of a closed position that ispast center, the linkage will not open absent a force applied to clamphandle 1206 to release clamp 1204. Thus, in a locked positionend-effector 602 may be robustly secured to robot atm 604.

Spring 1210 may be a curved beam in tension. Spring 1210 may becomprised of a material that exhibits high stiffness and high yieldstrain such as Virgin PEEK (poly-ether-ether-ketone). The linkagebetween end-effector 602 and robot arm 604 may provide for a sterilebarrier between end-effector 602 and robot arm 604 without impedingfastening of the two couplings.

The reinforcing coupling may be a linkage with multiple spring members.The reinforcing coupling may latch with a cam or friction basedmechanism. The reinforcing coupling may also be a sufficiently powerfulelectromagnet that will support fastening end-effector 102 to robot arm604. The reinforcing coupling may be a multi-piece collar completelyseparate from either end-effector 602 and/or robot arm 604 that slipsover an interface between end-effector 602 and robot arm 604 andtightens with a screw mechanism, an over center linkage, or a cammechanism.

FIG. 13 is a circuit diagram that illustrates power transfer betweenend-effector 602 and robot arm 604 consistent with an exemplaryembodiment. End-effector 602 may comprise a coil 1302, resistor 1304,and diode 1306. Robot arm 604 may comprise coil 1308 and voltage supply1310.

End-effector 602 and robot arm 604 may be configured in a manner toallow for wireless power transfer in order to power end-effector 602 andcomponents associated with end-effector 602. In an exemplary embodiment,end-effector 602 may comprise coil 1302 that receives an electromagneticfield generated by robot arm 604. Robot arm 604 may contain coil 1308,which may serve as a primary coil in an inductive power transfer systembetween robot arm 604 and end-effector 602 over an air gap. In anexemplary embodiment, the air gap may be in the range of 0.1-20 mm. Coil1308 may be coupled to voltage supply 1310 in order to generate theelectromagnetic field. The electromagnetic field may be received by coil1304 of end-effector 602 to generate an electrical current.

The inductive power relationship between may power components ofend-effector 602 such as tracking markers 702, sensor 902, and otherelectrical components associated with end-effector 602. By providingwireless powering, end-effector 602 may be physically and/orelectrically isolated from robot arm 604 while powering electronics andother components contained in end-effector 602.

The resistance of resistor 1304 may be varied among a number of distinctstates, causing differential power draw. The power draw may be measuredfrom the side of the surgical robot as a means of wirelessly passing asignal from end-effector 602 to the surgical robot base 610.Alternatively, a battery could be used to power the electronics, and astandard wireless communications protocol such as Bluetooth may be usedto exchange signals between end-effectuator 602 and robot base 612. Datatransferred to robot base 612 may include state information. Thisinformation may include a determination of whether end-effector 602 isdetached from robot arm 604, and if instrument 608 is present in guidetube 606.

The power transmission between robot arm 604 and end-effector 602 may bebased on electromagnetism, optics, or ultrasound. For each of thesetransmission types, the corresponding resistance on end-effector 602 canbe varied to communicate the state of end-effector 602. End-effector 602may propagate power or receive one or more signals by any of theaforementioned principles to other items in the sterile field, such asdrills, screw drivers, implant holders, or lights. In addition, powerand/or signal may be passed to other sterile items via a contactconnection.

Referring to FIGS. 14 and 15, prior to or during a surgical procedure,certain registration procedures may be conducted in order to trackobjects and a target anatomical structure of the patient both in anavigation space and an image space. In order to conduct suchregistration, a registration system 1400 may be used as illustrated inFIG. 14.

A patient fixation instrument 1402 may be secured to a rigid anatomicalstructure of the patient and a dynamic reference base (DRB) 1404 may beattached to patient fixation instrument 1402. For example, patientfixation instrument 1402 may be inserted into opening 1406 of dynamicreference base 1404. Dynamic reference base 1404 may contain markers1408 that are visible to tracking devices, such as tracking subsystem532. These markers may be optical markers or reflective spheres aspreviously discussed herein.

Patient fixation instrument 1402 is attached to a rigid anatomy of thepatient and may remain attached throughout the surgical procedure. In anexemplary embodiment, patient fixation instrument 1402 is attached to arigid area of the patient, for example a bone, that is located away fromthe targeted anatomical structure subject to the surgical procedure. Inorder to track the targeted anatomical structure, dynamic reference base1404 is associated with the targeted anatomical structure through theuse of a registration fixture that is temporarily placed on or near thetargeted anatomical structure in order to register the dynamic referencebase with the location of the targeted anatomical structure.

A registration fixture 1410 is attached to patient fixation instrument1402 through the use of a pivot arm 1412. Pivot arm 1412 is attached topatient fixation instrument 1402 by inserting patient fixationinstrument 1402 through an opening 1414 of registration fixture 1410.Pivot arm 1412 is attached to registration fixture 1410 by, for example,inserting a knob 1416 through an opening 1418 of pivot arm 1412.

Using pivot arm 1412, registration fixture 1410 may be placed over thetargeted anatomical structure and its location may be determined in animage space and navigation space using tracking markers or fiducials onregistration fixture 1410. Registration fixture 1410 may contain acollection of markers 1420 that are visible in a navigational space (forexample, markers 1420 may be detectable by tracking subsystem 532).Markers 1420 may be optical markers visible in infrared light aspreviously described herein. Registration fixture 1410 may also containa collection of fiducials 1422, for example bearing balls, that arevisible in an imaging space (for example, a three dimension CT image).As described in greater detail with respect to FIG. 15, usingregistration fixture 1410, the targeted anatomical structure may beassociated with dynamic reference base 1404 thereby allowing depictionsof objects in the navigational space to be overlaid on images of theanatomical structure. Dynamic reference base 1404, located at a positionaway from the targeted anatomical structure, may become a referencepoint thereby allowing removal of registration fixture 1410 and/or pivotarm 1412 from the surgical area.

FIG. 15 provides an exemplary method 1500 for registration consistentwith the present disclosure. Method 1500 begins at step 1502 wherein agraphical representation (or image(s)) of the targeted anatomicalstructure may be imported into system 300, for example computer 408. Thegraphical representation may be three dimensional CT or a fluoroscopescan of the targeted anatomical structure of the patient which includesregistration fixture 1410 and a detectable imaging pattern of fiducials1420.

At step 1504, an imaging pattern of fiducials 1420 is detected andregistered in the imaging space and stored in computer 408. Optionally,at this time at step 1506, a graphical representation of theregistration fixture may be overlaid on the images of the targetedanatomical structure.

At step 1508, a navigational pattern of registration fixture 1410 isdetected and registered by recognizing markers 1420. Markers 1420 may beoptical markers that are recognized in the navigation space throughinfrared light by tracking subsystem 532 via position sensor 540. Thus,the location, orientation, and other information of the targetedanatomical structure is registered in the navigation space. Therefore,registration fixture 1410 may be recognized in both the image spacethrough the use of fiducials 1422 and the navigation space through theuse of markers 1420. At step 1510, the registration of registrationfixture in the image space is transferred to the navigation space. Thistransferal is done, for example, by using the relative position of theimaging pattern of fiducials 1422 compared to the position of thenavigation pattern of markers 1420.

At step 1512, registration of the navigation space of registrationfixture (having been registered with the image space) is furthertransferred to the navigation space of dynamic registration array 1404attached to patient fixture instrument 1402. Thus, registration fixture1410 may be removed and dynamic reference base 1404 may be used to trackthe targeted anatomical structure in both the navigation and image spacebecause the navigation space is associated with the image space.

At steps 1514 and 1516, the navigation space may be overlaid on theimage space and objects with markers visible in the navigation space(for example, surgical instruments with optical markers). The objectsmay be tracked through graphical representations of the surgicalinstrument on the images of the targeted anatomical structure.

Registration is discussed in further detail with reference to FIGS.16-18. In preparation for navigated surgery and before 3D imaging hasoccurred, registration device 1600, which may be the same or similar toregistration fixture 1412 as noted with regard to FIG. 14, may betemporarily attached to a patient at a location which is in closeproximity to a target anatomy for surgery. Device 1600 may containradiopaque and retroreflective markers as discussed in further detailbelow.

Device 1600 may comprise a frame 1602. Frame 1602 may be strong andradiolucent material such as hard plastic or aluminum. Radiopaquespheres or makers 1604 may be used in frame 1602 and may be, forexample, 0.25″ diameter titanium ball bearings. Considerations inselecting the type of material for radiopaque spheres 1604 may includematerials that can be imaged in a manner that provides sufficientcontrast on a CT scan while limiting distortion or scatter. As shown inFIG. 16, device 1600 is shown containing seven (7) markers 1604 (forexample, titanium ball bearings) pressed into through-holes 1606 ondevice 1600; in an exemplary embodiment, these additional redundantmarkers are present for improved accuracy although only 4 markers arenecessary to account for the rigid body and compensate for mirroring(discussed below). Radiopaque markers 1604 may be pressed intothrough-holes 1606 instead of welded or glued to a surface, divots, orposts of frame 1602. This usage of through-holes may have the beneficialeffect of minimizing image distortion at a point of contact of markers1604 and the surrounding material of frame 1602 due to lack ofadditional welding material or bonding material at the marker-frameinterface. Because the marker 1604 is centered in the through-hole 1606symmetrically, any scatter or distortion that is present in the CT imagewill appear symmetrically around the image of the ball bearing, and sothe center of the ball bearing, identified as the center of the imageand noise cluster, will be more accurate.

Device 1600 may also include retroreflective spheres or markers 1608.For example, markers 1608 may be made of plastic, coated with glassparticles, and be roughly 15 mm in diameter. In an exemplary embodiment,device 1600 may have four (4) retroreflective spheres mounted to postsof device 1600 as shown in FIG. 16. Device 1600 may also include a starmount 1610 allowing discrete rotational positions of the device on aholder (not shown).

In device 1600, the radiopaque markers 1604 and retroreflective markers1608 are in a fixed and known position in reference to each other. Theserelative positions may be determined from design drawings, by using alaser scan or another type of scanning device, or by optically trackingthe four retroreflective markers 1608 while using a tracked probe totouch each radiopaque marker 1604, the positions of which may beelectronically sent to the robot system.

In order to register the patient anatomy, device 1600 may be placed onthe patient at an area near the target anatomy and a scanner (such as aCT scanner) may be positioned such that the area to be scanned (the scanvolume) contains both radiopaque markers 1604 and the target anatomy forsurgery (e.g., a particular vertebra of a patient). From the imagesproduced by the CT scan (the image volume), the 3D locations of thecenters of radiopaque markers 1604 are identified in the imagecoordinate system using image processing and edge detection. Before,during, or after the scan, using a stereophotogrammetric opticaltracking system, the 3D locations of the centers of retroreflectivemarkers 1608 are also found. Knowing the centers of radiopaque spheres1604 in the image coordinate system, the centers of retroreflectivespheres 1608 from the use of cameras detecting retroreflective sphere(for example, infrared cameras comprising a camera coordinate system),and the relative spatial locations of the retroreflective markers 1608and radiopaque markers 1604 with respect to each other, transformationor association of coordinates from the camera coordinate system to theimage coordinate system can be calculated (or vice versa). After thistransformation has been determined, registration of the patient anatomyis established.

After registration of the target anatomy is established and referencedto device 1600, a user may then transfer this registration to anotherarray of retroreflective markers. For example, as shown in FIGS. 17 and18, registration of a target anatomy 1700 may be transferred to anotherdevice such as DRB 1702 which may be the same or similar as DRB 1404 aspreviously described. After such transfer occurs, device 1600 may beremoved from the patient and the surgical field entirely.

DRB 1702 may be a bone-mounted tracker using for example patient fixtureinstrument 1706 of FIG. 18 (or patient fixture instrument 1402 aspreviously discussed) and be tracked by an optical tracking system (suchas the IR cameras as previously described). Relative positions ofmarkers 1608 of device 1600 with respect to markers 1704 of DRB 1702 maybecome known in the camera coordinate system and, therefore, thepositions of radiopaque markers 1604 relative to DRB 1702 may bedetermined based on the geometry of markers 1604 in relation to markers1608 and the spatial relationship of makers 1608 to markers 1704.Because the position of radiopaque markers 1604 at the time of the scanrelative to DRB 1702 remain in a constant fixed relative positionthroughout surgery, device 1600 can be removed after registrationtransfer to DRB 1702. The robot system may indicate that registration isbeing transferred to the DRB 1702 via a graphical indication on adisplay.

There are different manners in which device 1600 can be temporarilyplaced on the patient in order to conduct registration. One exemplarymanner involved adhering device 1600 to the skin of the patient. Device1600 can be attached temporarily to the patient's anatomy with either anadhesive backing that is pre-applied, or by overlaying device 1600 orcomponents of device 1600 with sterile tape or iodine-embedded surgicalfilm (e.g., Ioban; 3M Medical, St. Paul, Minn.).

In another exemplary embodiment, device 1600 may be attached to anatomyof the patient. Device 1600 may be set in place by attaching it to anextension of an adjacent pin or rigidly fixed reference base, such asfor example as shown in FIGS. 14 and 18. In this exemplary embodiment,device 1600 may not have to touch the patient and merely hover justabove the target anatomy being imaged. In an exemplary embodiment,features on the positioning arm may allow the user to loosen, forexample, set screws and adjust the position of device 1600, then tightenthe set screws to ensure that device 1600 does not move relative to DRB1702 until registration has been transferred.

In a further exemplary embodiment, device 1600 may have a non-co-planarlayout of radiopaque spheres 1604. Rather than being a flat, planardevice, device 1600 may be configured to have curved legs as shown inFIGS. 14 and 16. This configuration may address issues involving“mirroring” when loading medical image slices into a 3D volume. Withmirroring, the image slices are inadvertently sequentially loaded inreverse order. Thus, the x and y coordinates of each slice are correct,but the z coordinate is inverted. The result is that the loaded imagevolume is a mirror image of the actual anatomy. For any number ofradiopaque markers on the same plane representing a rigid body, acomparison of an expected template of 3D marker locations to theperceived 3D locations in the image volume would match in the mirrorimage but would misidentify one coordinate axis as positive instead ofnegative. In order to overcome such a problem and provide a safetycheck, the radiopaque markers are in different planes. Thus, if a mirrorimage is inadvertently loaded, the non-planar markers will not fit thetemplate and the image can be reloaded in the correct order.

One or more embodiments presented herein may allow for patient anatomyto be quickly and accurately registered to a fixed reference arrayregardless of the imaging system being used. This feature is incontrast, for example, to existing systems that use tracking cameras totrack the position of a marker array on the imaging system at the timeof the scan relative to a marker array on the patient in order toestablish registration of the tracking coordinate system with the imagecoordinate system. Most imaging systems do not have tracking markers andlack calibration of the image field to allow such a method to workuniversally. As discussed herein, one or more embodiments may uselocations of markers as detected from an image processing scan, whichdetermine if the scan volume is readable by the system.

Moreover, one or more embodiments herein allow a registration device tobe positioned where desired since it has its own tracking markers andwill later be removed. This is in contrast to other methods where abone-mounted tracking array, containing both retroreflective spheres andan extension or feature with radiopaque markers, is used forregistration and positioned relatively close to a tracking array,thereby having limited adjustability. This registration device couldeither inadvertently block the surgeon's access, obscure trackingmarkers, or require suboptimal positioning of the CT scanner to captureall the radiopaque spheres in the scan. One or more embodimentsdescribed herein may allow a registration device to be placed relativelyfar from a rigid tracking array, easily adjustable to be close to theskin, and removed from the path of surgery after registration transferto the tracking array.

It will be appreciated by those skilled in the art that while theinvention has been described above in connection with particularembodiments and examples, the invention is not necessarily so limited,and that numerous other embodiments, examples, uses, modifications anddepartures from the embodiments, examples and uses are intended to beencompassed by the claims attached hereto. The entire disclosure of eachpatent and publication cited herein is incorporated by reference, as ifeach such patent or publication were individually incorporated byreference herein. Various features and advantages of the invention areset forth in the following claims.

The invention claimed is:
 1. A surgical robot system comprising: adynamic reference base adapted to attach to a patient fixtureinstrument, wherein the dynamic reference base has referenceretroreflective markers, which are configured to be tracked by a camerasystem, indicating a position of the patient fixture instrument in acamera coordinate system associated with the camera system; a temporaryregistration fixture device adapted to be temporarily attached to thepatient and having: temporary retroreflective markers trackable by thecamera system, indicating a location of a target anatomical structure inthe camera coordinate system and radiopaque markers indicating alocation of the target anatomical structure in an image coordinatesystem defined by an imaging system, the temporary retroreflectivemarkers being in a fixed position relative to the radiopaque markers;wherein the surgical robot system has a processor configured to performan initial registration of the target anatomical structure from theimaging coordinate system to the camera coordinate system by associatinga spatial location of the radiopaque markers of the temporaryregistration fixture device in the image coordinate system to a spatiallocation of the retroreflective markers of the temporary registrationfixture device in the camera coordinate system based on the fixedposition relationship of the temporary retroreflective markers relativeto the radiopaque markers; wherein the processor of the surgical robotsystem is configured to transfer the initial registration of the targetanatomical structure relative to the temporary registration fixturedevice to a subsequent registration of the target anatomical structurerelative to the dynamic reference base based on a relative positionrelationship between the temporary retroreflective markers and thereference retroreflective markers; and wherein the dynamic referencebase is configured to track the target anatomical structure in thecamera coordinate system after the subsequent registration occurs. 2.The surgical robot system of claim 1, wherein the temporary registrationfixture device is adapted to removably attach to the patient inproximity to the target anatomical structure.
 3. The surgical robotsystem of claim 2, wherein the temporary registration fixture device isadapted to removably attach to the skin of the patient.
 4. The surgicalrobot system of claim 2, wherein the temporary registration fixturedevice is configured to hover or rest on the patient by being removablyattachable to the patient fixture instrument to provide the fixedposition relationship between the temporary retroreflective markers andthe reference retroreflective markers.
 5. The surgical robot system ofclaim 2, wherein the temporary registration fixture device is removedfrom the patient after the initial registration of the target anatomicalstructure is transferred to the subsequent registration relative to thedynamic reference base.
 6. The surgical robot system of claim 1, whereinthe camera system has one or more infrared cameras configured to trackthe location of the reference retroreflective markers of the dynamicreference base and the temporary retroreflective markers of thetemporary registration fixture device.
 7. The surgical robot system ofclaim 1, wherein the temporary registration fixture device comprises anon-co-planar arrangement of the temporary radiopaque markers.
 8. Thesurgical robot system of claim 1, wherein the processor is furtherconfigured to indicate through a display that registration of the targetanatomical structure has been transferred from the temporaryregistration fixture device to the dynamic reference base.
 9. Thesurgical robot system of claim 1, wherein the transfer of registrationof the target anatomical structure is based upon a geometricrelationship of the temporary retroreflective markers of theregistration fixture device to the reference retroreflective markers ofthe dynamic reference base.
 10. The surgical robot system of claim 1,wherein the dynamic reference base is positioned in a location differentfrom the target anatomical structure.
 11. The surgical robot system ofclaim 1, wherein the dynamic reference base is adapted to attach to thepatient at a location different from the target anatomical structure.12. A surgical robot system comprising: a temporary registration fixtureadapted to be temporarily attached to a patient and having initialoptical markers trackable by a camera system and radiopaque markersdetectable by image analysis and at a fixed position from the initialoptical markers; a dynamic reference base adapted to attach to a patientfixture and having reference optical markers trackable by the camerasystem; a processor configured to perform an initial registration of atarget anatomical structure from an imaging coordinate system to acamera coordinate system based on: detection of the radiopaque markerscontained in an image of the anatomical structure taken by an imagingsystem; detection of the initial optical markers by the camera system;and the fixed position relationship between the radiopaque markers andthe initial optical markers; wherein the processor is further configuredto transfer the initial registration to a subsequent registration of thetarget anatomical structure relative to the dynamic reference base basedon a relative position relationship between the initial optical markersand the reference optical markers.
 13. The surgical robot system ofclaim 12, wherein: the processor performs the initial registration froma 3-dimensional CT image containing the temporary registration fixture;the processor performs the subsequent registration based on relativepositions of the temporary optical markers and the reference opticalmarkers simultaneously tracked by the camera system.
 14. The surgicalrobot system of claim 12, wherein the temporary registration fixture isadapted to be temporarily to the patient fixture of the dynamicreference base during the process of transferring the initialregistration to the subsequent registration.
 15. The surgical robotsystem of claim 12, wherein the temporary registration fixture has aplurality of holes through which the radiopaque markers are inserted.16. The surgical robot system of claim 15, wherein the radiopaquemarkers are positioned in a non-coplanar manner.